Mattress pad with latex liner

ABSTRACT

A padded mattress cover for a mattress has a top panel with a first perimeter, a first rope attached to the top panel along the first perimeter, and a gusset attached to the first rope. A second rope is attached to the gusset opposite the first rope and a bottom panel with a second perimeter is attached to the second rope along the second perimeter, the bottom panel being opposed to the top panel to form an interior within the cover. A latex layer is positioned beneath the top panel and within the interior. A non-woven layer is positioned beneath the latex layer and within the interior. Finally, a plurality of puff balls are positioned between the non-woven layer and the bottom panel. The padded mattress cover may be positioned on a mattress with the bottom panel adjacent said mattress to cover said mattress.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to Chinese Patent Application No.______ filed Sep. 25, 2009, the disclosure of which is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

Padded mattress covers are a common part of the under coverings on which bed linens are placed or fitted. Such mattress covers were conventionally relatively thin and were used solely to protect the mattress. In recent years, however, mattress covers have been adopted include thicker padding to increase user comfort and extend the life of the underlying mattress. Another reason is to provide isolation and insulation between the mattress and the user.

Conventional fill materials for such mattress covers vary from polyester to down, or even trapped air. These fillers are lightweight and have exceptional air-trapping capacity that creates an insulation barrier within the padded mattress cover's shell that contains the filler. The height of this insulation barrier, commonly referred to as loft, is important. Generally, the thicker the fill, or the greater the loft, the greater the insulation and comfort factor.

One downside of using polyester, down, or even air fill is that none of these materials is hypo-allergenic, anti-microbial, or dust mite resistant. Thus, for extended use as bedding materials they are not necessarily the most ideal products. Lofty materials also require greater sized packaging, which negatively affects available shelf space and transport of the covers.

It would therefore be advantageous to provide a padded mattress cover that includes the insulating and comfort qualities of a lofty polyester or down, while needing less loft producing materials, while also being hypo-allergenic, anti-microbial, or dust mite resistant.

SUMMARY OF THE INVENTION

To fulfill this need, and in accordance with one aspect of the present invention, there is provided a padded mattress cover for covering a mattress. The padded mattress cover has a top panel with a first perimeter, a first rope attached to the top panel along the first perimeter, a gusset attached to the first rope, a second rope attached to the gusset opposite the first rope, and a bottom panel having a second perimeter, the bottom panel being attached to the second rope along the second perimeter. The bottom panel is opposed to the top panel to form an interior within the top panel, the gusset, and the bottom panel. The padded mattress cover also has a latex layer positioned beneath the top panel and within the interior, a non-woven layer positioned beneath the latex layer and within the interior, and a plurality of puff balls positioned between the non-woven layer and the bottom panel. The padded mattress cover may be positioned on a mattress with the bottom panel adjacent the mattress to cover the mattress.

The latex layer may comprise approximately 40-60% of the interior with the puff balls comprising approximately the remainder.

The latex layer and the non-woven layer may be sewn to the top panel within the perimeter.

The cover may further comprise a skirt extending from the second rope.

The puff balls may be formed from latex.

The padded mattress cover may be hypo-allergenic, anti-microbial, or dust mite resistant.

The top panel, latex layer, and non-woven layer may be breathable.

The padded mattress cover may further comprise a second non-woven layer adjacent the first non-woven layer. If so provided, the latex layer and the non-woven layers may be sewn to the first rope and the second rope.

The latex layer may be an open cell latex.

In accordance with a further aspect of the present invention, a padded mattress cover comprises a top panel, a bottom panel secured to the top panel around a perimeter thereof, and a layer of latex positioned between the top and bottom panels.

The layer of latex may be open cell latex.

The cover may further comprise at least one non-woven layer, the at least one non-woven layer positioned between the latex layer and the bottom panel.

The cover may further comprise a gusset connected between the perimeters of the top panel and the bottom panel, the gusset forming an available loft, the layer of latex at least partially filling the available loft. If so provided, the cover may further comprise a first rope connected between the top panel and the gusset, wherein the latex layer is sewn to the first rope. The cover may further comprise a second rope connected between the gusset and the bottom panel, wherein the latex layer is sewn to the first rope and the second rope.

The cover may further comprise a plurality of puff balls between the latex layer and the bottom panel. If so provided, the cover may also include a non-woven layer between the latex layer and the puff balls, wherein the puff balls are at least partially secured in a plurality of chambers formed by the non-woven layer and the bottom panel. The puff balls may comprise approximately 40-60% of the inner volume of the padded mattress cover and the latex layer may comprise approximately the remaining inner volume.

The latex layer may be approximately ¼″ thick.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages and features of the invention are described with reference to exemplary embodiments, which are intended to explain and not to limit the invention, and are illustrated in the drawings in which:

FIG. 1 is a partial, perspective view of an exemplary padded mattress cover in accordance with the present invention;

FIG. 2 is a partial cutaway view of the padded mattress cover of FIG. 1, taken along section line A-A.

DETAILED DESCRIPTION

The following discussion describes, in detail, various aspects and embodiments of the present invention. This discussion should not be construed as limiting the invention to those particular aspects or embodiments. Rather, practitioners skilled in the art will recognize numerous other aspects and embodiments as well, which are within the scope of the present invention.

In describing the preferred embodiments of the present invention illustrated in the drawings, specific terminology will be used for the sake of clarity. However, the present invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.

For purposes of explanation, the invention is specifically described herein with regard to padded mattress covers. However, it is to be understood that any number of bedding material articles may utilize the same teachings, for example mattress toppers that are formed integrally with a mattress.

The exemplary embodiment of the present invention shown in FIGS. 1 and 2 comprises a padded mattress cover 10 (also referred to as a mattress pad 10), which can be removably disposed onto a mattress or other bed equipment. Advantages of being removable include the ability to store and/or clean the padded mattress cover as well as allow the mattress to be flipped over during its usable life, while still retaining a padded mattress look and feel. Another advantage is that the padded mattress cover can be used on more than one mattress of the same or similar size.

As shown in FIGS. 1 and 2, the preferred padded mattress cover 10 comprises a padded portion 12 and a skirt 14. The padded portion 12 comprises a top panel 16, a bottom panel 18 (see FIG. 2) and a gusset 20 secured between the top panel and bottom panel. As known in the art, the gusset 20 provides room for various layers of internal materials, described below. Each of the top and bottom panels 16, 18, and the gusset 20 may be manufactured from any type of suitable material such as any conventional bed clothing cloth like cotton, wool, silk, polyester, or any combination of the aforementioned materials. Other materials will also be readily apparent to one skilled in the art. In a most preferred embodiment, the top panel 16 is formed from 100% cotton and the bottom panel 18 is formed from 100% polyester.

Around the perimeter junction between the top panel 16 and the gusset 20, and then again between the gusset 20 and the bottom panel 18, are optionally sewn in two ropes 22 a, 22 b. Although these ropes 22 a, 22 b function to help bolster the connection between the top panel 16, gusset 20, and bottom panel 18, they are primarily provided for aesthetic purposes and may be manufactured from satin or silk-like materials, in addition to conventional materials listed above, such as wool, cotton, and polyester. It will be appreciated that the bottom rope 22 b is also utilized to help support the skirt 14. In other embodiments, ropes 22 a, 22 b may not be provided and the remaining elements, may be sewn directly to themselves. In preferred embodiments, the ropes 22 a, 22 b are formed from ⅛″ satin cord.

In the embodiment shown in FIGS. 1 and 2, the skirt 14 is a conventional skirt and includes an elastic band 24 at its inside end 26. The skirt 14 may be sized to accommodate various height mattresses, and includes an exposed side 28 and an underside 30, the underside extending beneath a mattress M. Like the panels 16, 18, the skirt 14 may be manufactured from a variety of materials including cotton, wool, silk, polyester, or any combination of the aforementioned materials. In a preferred embodiment, the skirt 14 is formed from 95% polyester and 5% spandex having 2-way stretch capabilities.

Within the gusseted area of the padded portion 12, the mattress pad 10 comprises several layers. The initial layer, or upper most layer, has already been discussed, and is the top panel 16. Beneath the top panel 16 is provided a layer of latex 32. The latex layer 32 is preferably configured as open cell foam which is breathable, and may be approximately ⅛″ to ½″ inch thick. Other thicknesses may also be utilized, for example 1/16″ through 1″ or more. In a preferred embodiment, the latex layer 32 is ¼″ thick.

Although it need not be, the latex layer 32 is preferably sewn directly to both of the ropes 22 a, 22 b with stitching 34. This configuration strengthens the connection of the latex layer 32 to the remainder of the padded mattress 10, and also helps to define the loft of the padded portion 12 for structural and aesthetic purposes. In this regard, the latex layer helps to keep the gusset fully extended and presents a nicely finished overall look to the padded mattress cover.

Preferably, immediately below the latex layer 32 are two layers of non-woven fabric, formed as an upper non-woven layer 36 and a lower non-woven layer 38. Each of these layers is also preferably sewn to both ropes 22 a, 22 b. These non-woven layers 36, 38 are typically breathable to permit air to pass, and are preferably formed from 100% polyester, although other materials such as cotton, silk, wool, or the like may be utilized.

It will be appreciated that the latex layer 32, upper non-woven layer 36, and lower non-woven layer 38 are preferably therefore secured to the padded mattress 10 at least generally at their perimeters, where they meet the ropes 22 a, 22 b. In preferred embodiments, they may also be sewn to the top panel 16 by quilting or other stitching means 42. However, in other embodiments they may not be sewn and instead are permitted to float relative to the top layer 16. Finally, in still further embodiments only the latex layer 36 or the latex layer and the upper non-woven layer 36 may be sewn to the top layer 16 by stitching 42.

Beneath the lower non-woven layer 38 is a layer of puff balls 40. In preferred embodiments, the puff ball layer is comprised of a series of small puff-blown polyester balls 41. Such fiberfill is known in the art to be resilient, fluffable, and shapeable, much like natural down. This puff ball layer is preferably filled such that it represents 40% of the inner volume of the padded portion 12, with the latex layer 32 comprising roughly the remaining 60%, or vice versa. In other embodiments, the percentage ranges can vary from virtually zero to 100% for either element, but generally a range from 40% to 60% for either element is preferred. In other embodiments, the puff balls 41 themselves may be configured from latex, such as puff-blown latex.

Beneath the puff ball layer 40 is the bottom panel 18. As discussed above, the bottom panel is typically only sewn to the lower-most rope 22 b. Likewise, it is also not typically secured to any other element except at this outside perimeter connection, thus permitting the inner portions, particularly the puff ball layer 40, to float relative to the other elements. In still further embodiments, the bottom panel 18 may be sewn to at least the lower non-woven layer 38 in a manner to create open chambers (not shown). Such open chambers may comprise a large percentage of closed stitching, which prevents the puff balls 41 from moving from one chamber to an adjacent chamber. But, the chambers may also be partially opened, to permit some level of migration. Typically, the openings only represent approximately 5-20% of the overall channel perimeter to limit too much migration, while still permitting some. Such openings also permit a user to manually move puff balls 41 from one chamber to another if desired.

In use, a user will typically lay on the padded mattress cover after the cover is placed on a mattress. By positioning the latex layer between the user and the puff ball layer, the mattress pad may be provided with a lesser quantity of puff ball while still providing equivalent loft, insulation, and comfort level characteristics as a conventional padded mattress cover with no latex layer. This is due in part because of the structural qualities of the latex foam and its ability to mold to a user's body while being structurally resilient. This also permits an equivalently performing padded mattress cover to have a lesser volume than a conventional mattress cover, which is beneficial for transport and reduced shelf space.

Moreover, the latex layer permits the mattress pad to remain air permeable, such that the mattress pad can breath. Latex itself is hypo-allergenic, anti-microbial, and dust mite resistant. However, the breathability also helps to contribute to the complete mattress pad being hypo-allergenic, anti-microbial, and dust mite resistant. In addition, the breathability of latex keeps the user warm in the winter and cool in the summer. These features could not be achieved if conventional rubber materials were utilized in lieu of latex, as such materials are air-tight and are not hypo-allergenic, anti-microbial, and dust mite resistant.

While the exemplary embodiment of the mattress pad 10 has been described with a single latex layer 32, it will be appreciated that multiple latex layers 32 may also be provided. These layers may directly abut each other or there may be other layers in between, such non-woven layers or additional puff ball layers. Additionally, it will be appreciated that although the mattress pad 10 has been described with multiple non-woven layers 36, 38, it will be appreciated that the mattress pad may include no non-woven layers, or more than two non-woven layers.

Likewise, a skirt 14 may also not be provided. In such embodiments, the mattress pad 10 may be configured to rest directly on the mattress M without additional support. Alternatively, support systems such as conventional straps and the like may be utilized to prevent relative movement between the mattress pad 10 and the mattress M.

Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. 

1. A padded mattress cover for covering a mattress comprising: a top panel having a first perimeter; a first rope attached to said top panel along said first perimeter; a gusset attached to said first rope; a second rope attached to said gusset opposite said first rope; a bottom panel having a second perimeter, the bottom panel attached to said second rope along said second perimeter, the bottom panel opposed to said top panel to form an interior within said top panel, said gusset, and said bottom panel; a latex layer positioned beneath said top panel and within said interior; a non-woven layer positioned beneath said latex layer and within said interior; and, a plurality of puff balls positioned between said non-woven layer and said bottom panel; wherein the padded mattress cover may be positioned on a mattress with said bottom panel adjacent said mattress to cover said mattress.
 2. The padded mattress cover of claim 1, wherein said latex layer comprises approximately 40-60% of said interior and said puff balls comprise approximately the remainder.
 3. The padded mattress cover of claim 1, wherein said latex layer and said non-woven layer are sewn to said top panel within said perimeter.
 4. The padded mattress cover of claim 1, further comprising a skirt extending from said second rope.
 5. The padded mattress cover of claim 1, wherein said puff balls are formed from latex.
 6. The padded mattress cover of claim 1, wherein said padded mattress cover is hypo-allergenic, anti-microbial, or dust mite resistant.
 7. The padded mattress cover of claim 1, wherein the top panel, latex layer, and non-woven layer are breathable.
 8. The padded mattress cover of claim 1, further comprising a second non-woven layer adjacent said first non-woven layer.
 9. The padded mattress cover of claim 8, wherein said latex layer and said non-woven layers are sewn to said first rope and said second rope.
 10. The padded mattress cover of claim 1, wherein said latex layer is an open cell latex.
 11. A padded mattress cover for covering a mattress, comprising: a top panel; a bottom panel secured to said top panel around a perimeter thereof; a layer of latex positioned between said top and bottom panels.
 12. The padded mattress cover of claim 11, wherein said layer of latex is open cell latex.
 13. The padded mattress cover of claim 11, further comprising at least one non-woven layer, said at least one non-woven layer positioned between said latex layer and said bottom panel.
 14. The padded mattress cover of claim 11, further comprising a gusset connected between the perimeters of said top panel and said bottom panel, the gusset forming an available loft, the layer of latex at least partially filling the available loft.
 15. The padded mattress cover of claim 14, further comprising a first rope connected between said top panel and said gusset, wherein said latex layer is sewn to said first rope.
 16. The padded mattress cover of claim 15, further comprising a second rope connected between said gusset and said bottom panel, wherein said latex layer is sewn to said first rope and said second rope.
 17. The padded mattress cover of claim 11, further comprising a plurality of puff balls between said latex layer and said bottom panel.
 18. The padded mattress cover of claim 17, further comprising a non-woven layer between said latex layer and said puff balls, wherein said puff balls are at least partially secured in a plurality of chambers formed by said non-woven layer and said bottom panel.
 19. The padded mattress cover of claim 17, wherein said puff balls comprise approximately 40-60% of the inner volume of said padded mattress cover and said latex layer comprises approximately the remaining inner volume.
 20. The padded mattress cover of claim 11, wherein said latex layer is approximately ¼″ thick. 